Pressure-Activated Locking Fluid Connection for Large-Diameter Sealing
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Solution Overview
Problem
Conventional wellhead connections for pressure control equipment pose safety risks to operators due to high pressures and large diameters, and existing fluid connections struggle to consistently maintain high pressures in larger diameters, especially during hydraulic fracturing operations.
Innovation Solution
A remotely-operated fluid connection assembly with a fluid connection adapter and housing assembly that uses internal working pressure to tighten seals, featuring a tapered lock engagement surface, locking elements, and a high-strength sleeve to enhance seal performance and robustness, allowing for higher pressure retention and remote operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hand union or hammer union connections are used, then the connection can be made with simple structure, but the operator safety deteriorates due to exposure to high pressure and suspended loads
Solution Approach 1:
The connection system is divided into separate functional components: a quick-connect coupling mechanism for rapid attachment, a locking mechanism with multiple locking elements distributed around the circumference, and a seal system. This segmentation allows the operator to make connections without manual tightening while maintaining safety through distributed locking points.
Solution Approach 2:
The manual mechanical tightening process (knock wrench with sledgehammer) is replaced with a self-actuating locking mechanism that uses the insertion motion itself to engage locking elements and seals. The system substitutes human-operated mechanical fastening with an automatic mechanical interlocking system that locks upon insertion.
2Productivity
If fluid connections are designed for larger diameters to accommodate hydraulic fracturing, then the flow capacity is improved, but the ability to maintain high pressure deteriorates
Solution Approach 1:
The connection system employs different sealing strategies at different locations: primary seals at the interface between mating components, secondary seals as backup, and seal elements with varying cross-sectional areas optimized for local pressure conditions. This local differentiation of seal quality allows large diameter connections to maintain high pressure by addressing leakage at each critical location with appropriately sized and positioned seals.
Solution Approach 2:
The seal system uses composite sealing approaches combining multiple seal materials and types (e.g., elastomeric O-rings, metal-to-metal seals, and polymer seals) within the same connection. This composite sealing strategy provides redundancy and ensures pressure retention across the full range of operating conditions for large diameter, high pressure applications.
3Device complexity
If manual tightening with knock wrench is used, then the device complexity is low, but the operator safety deteriorates due to physical danger from suspended loads and high pressure
Solution Approach 1:
The connection system is designed to self-lock upon insertion without requiring external tightening tools or manual intervention. The locking elements automatically engage with the mating component's locking surfaces as the components are brought together, and the seals are compressed by the insertion force itself. This self-service mechanism eliminates the need for operators to position themselves in dangerous zones with suspended loads.
Solution Approach 2:
The locking elements and seals are pre-positioned and pre-loaded during assembly so that the act of insertion itself activates the locking and sealing functions. The system performs the tightening and locking actions in advance of any pressure application, ensuring the connection is secure before high pressure or suspended loads are involved in the operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved seal performance and safety by maintaining high pressures in larger diameters, reducing the risk of injury to operators and enhancing the reliability of fluid connections in high-pressure, high-flow applications like hydraulic fracturing.
Implementation Method 1
The seal is disposed to expand radially and tighten sealing contact responsive to introduction of internal pressure within the adapter
Data Source
AI summary
A remotely-operated fluid connection assembly to hold higher internal pressures in larger diameters. The assembly comprises a fluid connection adapter and a fluid connection housing assembly. When the adapter enters the housing assembly: (A) locking elements on the housing assembly constrict about the adapter; and (B) at least a first seal section on the adapter sealingly contacts a first seal bore on the housing assembly. Progressive engagement of a locking ring upon the locking elements urges the locking elements to tighten against the adapter. Internal pressure encourages adapter displacement, which then further tightens the adapter against the locking elements as now restrained by the locking ring. Internal pressure further encourages the first seal section on the adapter to expand radially to tighten the contact with the first seal bore in the housing assembly.